Condensate shield with fastener-free attachment for multi-poise furnace coils

Abstract

A shield for an evaporator assembly is configured to be attachable to a coil slab of a multi-poise coil without requiring the use of any fasteners. The shield comprises a first extension member, a second extension member, a bottom member disposed between the first and second extension members, and a lip member extending from the extension member. The first extension member is configured to be positioned on an inner surface of the coil slab. The lip member is configured to be positioned on an outer surface of the coil slab.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of an evaporator assembly, which includes an evaporator coil and condensate pan disposed within a casing.

FIG. 1B is an exploded perspective view of the evaporator assembly of FIG. 1A.

FIG. 2A is an exploded perspective view of an evaporator coil slab and the condensate pan of FIG. 1A.

FIG. 2B is a perspective view of an alternative embodiment of an evaporator coil slab exploded from the condensate pan.

FIG. 3 is a cross-sectional view of the evaporator assembly of FIGS. 1A and 1B.

FIG. 4 is a top view of the condensate pan.

FIG. 5 is a cross-sectional view of a corner section of the evaporator assembly shown in FIG. 3.

FIG. 6 is a perspective view of a bottom side of the condensate pan.

FIG. 7A is a perspective view of a shield.

FIG. 7B is a side view of the shield of FIG. 7A.

FIGS. 8A-8B illustrate a first step of attaching the shield onto a bottom of a coil slab. FIGS. 9A-9B illustrate a second step of attaching the shield onto the bottom of the coil slab.

FIGS. 10A-10B illustrate a third step of attaching the shield onto the bottom of the coil slab.

FIG. 11A is a perspective view of an alternative embodiment of a shield.

FIG. 11B is a side view of the shield of FIG. 11A.

FIGS. 12A-12B show the shield of FIG. 11A attached onto a bottom of a coil slab.

FIG. 13 is a cross-sectional view of the shield of FIG. 11A attached to a coil slab having three rows of coils.

FIG. 14 is a perspective view of a condensate pan insert for the evaporator assembly.

FIG. 15A is an enlarged perspective view of the evaporator assembly showing the condensate pan and pan insert.

FIG. 15B is a sectional view showing the condensate pan insert secured to a front pan member of the condensate pan.

FIG. 16 is a perspective view of a corner section of the evaporator assembly showing a delta plate prior to insertion into a first corner groove of the condensate pan.

FIG. 17 is a side view of a corner portion of the delta plate coupled to a coil slab.

FIG. 18 is a side view of the corner section of the evaporator assembly shown and described above in reference to FIG. 16 after the delta plate has been inserted into the first corner groove.

FIG. 19A is a front view of a vertical condensate pan.

FIG. 19B is a front view of the vertical condensate pan of FIG. 19A coupled to a horizontal condensate pan.

FIG. 20 is a perspective view of a corner portion of the vertical condensate pan coupled to the horizontal condensate pan.

Claims

1. A shield attachable to a coil slab in an evaporator assembly for directing condensation into a condensate pan, the shield comprising: a first extension member configured to be positioned on an inner surface of the coil slab;a second extension member;a bottom member disposed between the first and second extension members; anda lip member extending from the second extension member, the lip member configured to be positioned on an outer surface of the coil slab.

2. The shield of claim 1, wherein the first extension member and the second extension member are configured to secure the shield to the coil slab when the first and second extension members are positioned on the inner and outer surfaces of the coil slab, respectively.

3. The shield of claim 1, wherein the first extension member and the second extension member are configured to flex with respect to the bottom member in order to provide a spring-fit connection between the shield and the coil slab.

4. The shield of claim 1, wherein the bottom member further comprises a plurality of apertures, the apertures being configured to drain condensation formed on the coil slab into the condensate pan.

5. The shield of claim 4, wherein the apertures comprise a plurality of elongated slots.

6. The shield of claim 4, wherein the apertures comprise a plurality of channel members.

7. The shield of claim 1, wherein the shield is formed from a thin sheet of metal.

8. The shield of claim 7, wherein the metal comprises aluminum.

9. The shield of claim 1, wherein the bottom member of the shield further comprises an inside bottom portion and an outside bottom portion oriented at an angle with respect to the inside bottom portion.

10. The shield of claim 9, wherein a plurality of apertures are positioned along the inside bottom portion of the bottom member.

11. The shield of claim 1, wherein the lip member includes a tab configured to engage with a tube sheet attached to the coil slab.

12. The shield of claim 11, wherein the tube sheet includes a notch configured to receive the tab.

13. The shield of claim 11, wherein the lip member includes a second tab configured to engage with a second tube sheet attached to the coil slab.

14. The shield of claim 13, wherein the second tube sheet includes a notch configured to receive the second tab.

15. An evaporator assembly comprising: a coil slab including a first side and a second side opposing the first side;a condensate pan configured to receive a lower end of the coil slab;a shield disposed between the coil slab and the condensate pan for directing condensation from the coil slab into the condensate pan;a protrusion attached to the shield; anda first tube sheet coupled to the first side of the coil slab, wherein the tube sheet includes a first aperture configured to receive the protrusion.

16. The evaporator assembly of claim 15, and further comprising: a second protrusion attached to the shield; anda second tube sheet coupled to the second side of the coil slab, wherein the second tube sheet includes a second aperture configured to receive the second protrusion.

17. The evaporator assembly of claim 15, wherein the shield comprises: a first extension member configured to be positioned on an inner surface of the coil slab;a second extension member configured to be positioned on an outer surface of the coil slab; anda bottom member disposed between the first and second extension members.

18. The evaporator assembly of claim 17, wherein the first extension member and the second extension member are configured to flex with respect to the bottom member in order to provide a spring-fit connection between the shield and the coil slab.

19. The evaporator assembly of claim 15, wherein the shield comprises a plurality of apertures, the apertures being configured to drain condensation formed on the coil slab into the condensate pan.

20. The evaporator assembly of claim 19, wherein the apertures comprise a plurality of channel members.